Pub Date : 2026-01-18DOI: 10.1016/j.jmapro.2026.01.055
Ce Xiao , Rongkang Han , Xue Dang , Yichen Han , Jinke Zhang , Pengyu Wang , Jinxin Liu , Yanjin Lu
Laser powder bed fusion (LPBF) processed Ti-1Al-8V-5Fe (Ti-185) alloy presents significant engineering potential as a high-strength, lightweight, and cost-effective beta-Ti titanium alloy. However, compared to LPBF-processed Ti alloys (e.g., Ti-6Al-4V), research on the microstructural and defect formation mechanisms of LPBF-processed Ti-185 alloy, and their effects on mechanical properties, remains limited. Defect analysis via X-ray computed tomography (X-CT) demonstrated that insufficient laser energy density leads to a large number of lack-of-fusion (LOF) defects, whereas excessive laser energy density produces smaller, highly spherical pores. In-situ X-CT tensile tests revealed that with insufficient laser energy, cracks initiate and propagate at the edges of large LOF defects under very small gauge strain, resulting in quasi-brittle fracture, while the high density of pores associated with excessive laser energy accelerates crack propagation, resulting primarily in reduced ductility rather than a decrease in strength. This study provides a comprehensive understanding of the influence of laser energy density on the mechanical behavior of LPBF-processed Ti-185 alloy, offering valuable insights for optimizing processing parameters and expanding its engineering applications.
{"title":"3D characterization of laser energy density effects on mechanical behavior in laser powder bed fused Ti-185 alloy via in-situ X-ray tomography","authors":"Ce Xiao , Rongkang Han , Xue Dang , Yichen Han , Jinke Zhang , Pengyu Wang , Jinxin Liu , Yanjin Lu","doi":"10.1016/j.jmapro.2026.01.055","DOIUrl":"10.1016/j.jmapro.2026.01.055","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) processed Ti-1Al-8V-5Fe (Ti-185) alloy presents significant engineering potential as a high-strength, lightweight, and cost-effective beta-Ti titanium alloy. However, compared to <span><math><mrow><mi>α</mi><mo>+</mo><mi>β</mi></mrow></math></span> LPBF-processed Ti alloys (e.g., Ti-6Al-4V), research on the microstructural and defect formation mechanisms of LPBF-processed Ti-185 alloy, and their effects on mechanical properties, remains limited. Defect analysis via X-ray computed tomography (X-CT) demonstrated that insufficient laser energy density leads to a large number of lack-of-fusion (LOF) defects, whereas excessive laser energy density produces smaller, highly spherical pores. In-situ X-CT tensile tests revealed that with insufficient laser energy, cracks initiate and propagate at the edges of large LOF defects under very small gauge strain, resulting in quasi-brittle fracture, while the high density of pores associated with excessive laser energy accelerates crack propagation, resulting primarily in reduced ductility rather than a decrease in strength. This study provides a comprehensive understanding of the influence of laser energy density on the mechanical behavior of LPBF-processed Ti-185 alloy, offering valuable insights for optimizing processing parameters and expanding its engineering applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 317-333"},"PeriodicalIF":6.8,"publicationDate":"2026-01-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024763","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-18DOI: 10.1016/j.jmapro.2026.01.044
Guanzhong Hu, Wenpan Li, Rujing Zha, Ping Guo
Directed energy deposition (DED), a metal additive manufacturing process, is highly susceptible to process-induced defects such as geometric deviations, lack of fusion, and poor surface finish. This work presents a build-height-synchronized fringe projection system for in-situ, layer-wise surface reconstruction of laser-DED components, achieving a reconstruction accuracy of . From the reconstructed 3D morphology, two complementary geometry-based point-cloud metrics are introduced: local point density, which highlights poor surface finish, and normal-change rate, which identifies lack-of-fusion features. These methods enable automated, annotation-free identification of common deposition anomalies directly from reconstructed surfaces, without the need for manual labeling. By directly linking geometric deviation to defect formation, the approach enables precise anomaly localization and advances the feasibility of closed-loop process control. This work establishes fringe projection as a practical tool for micrometer-scale monitoring in DED, bridging the gap between process signatures and part geometry for certifiable additive manufacturing.
{"title":"Layer-wise anomaly detection in directed energy deposition using high-fidelity fringe projection profilometry","authors":"Guanzhong Hu, Wenpan Li, Rujing Zha, Ping Guo","doi":"10.1016/j.jmapro.2026.01.044","DOIUrl":"10.1016/j.jmapro.2026.01.044","url":null,"abstract":"<div><div>Directed energy deposition (DED), a metal additive manufacturing process, is highly susceptible to process-induced defects such as geometric deviations, lack of fusion, and poor surface finish. This work presents a build-height-synchronized fringe projection system for in-situ, layer-wise surface reconstruction of laser-DED components, achieving a reconstruction accuracy of <span><math><mrow><mo>±</mo><mtext>46</mtext><mspace></mspace><mtext>µm</mtext></mrow></math></span>. From the reconstructed 3D morphology, two complementary geometry-based point-cloud metrics are introduced: local point density, which highlights poor surface finish, and normal-change rate, which identifies lack-of-fusion features. These methods enable automated, annotation-free identification of common deposition anomalies directly from reconstructed surfaces, without the need for manual labeling. By directly linking geometric deviation to defect formation, the approach enables precise anomaly localization and advances the feasibility of closed-loop process control. This work establishes fringe projection as a practical tool for micrometer-scale monitoring in DED, bridging the gap between process signatures and part geometry for certifiable additive manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 334-346"},"PeriodicalIF":6.8,"publicationDate":"2026-01-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024730","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-17DOI: 10.1016/j.jmapro.2026.01.046
Chaoqun Wu , Yi Chen , Minghui Yang , Yufei Tang , Yun Cheng
The network-structured TiBw/TA15 composites are promising for aerospace but difficult to micromachining. Minimum quantity lubrication (MQL) is attractive for composites machining, yet its effect on surface quality in TiBw/TA15 micromilling remains unclear. The multiphase microstructures of TiBw/TA15 induce brittle-plastic removal and accelerates tool wear. Consequently, the MQL lubrication and tool wear are tightly coupled in evaluating surface quality, the mechanistic elucidation of MQL and machining-parameter effects remain challenging. To address this gap, this study integrates the computational fluid dynamics (CFD) modeling of oil-mist delivery with finite-element analysis (FEA) of multiphase material removal to interpret the results of systematic micromilling experiments across increasing cutting distances. The results show that MQL improves surface quality relative to dry cutting by suppressing the irregular plastic flow of TA15, while TiBw fractures remain but contribute less to surface roughness. The parameter effects are stage-dependent: In initial wear (≤20 mm), radial cutting depth governs the surface roughness through lubrication effectiveness and tool edge geometry, and a moderate value of 60 μm is recommended. In stable wear (>20 mm), spindle speed becomes dominant by altering the lubricant residence and matrix plastic deformation, and the high value of 30,000 rpm is discouraged. A small feed rate (3 μm/tooth) is not recommended due to the intensified ploughing effect and tool wear. MQL ensures consistent surface roughness values remaining under 300 nm, even as tool wear occurs. These findings could provide critical guidance for precision machining of TiBw/TA15 composites.
{"title":"Effect of minimum quality lubrication on micromilling of TiBw/TA15 composites considering tool wear","authors":"Chaoqun Wu , Yi Chen , Minghui Yang , Yufei Tang , Yun Cheng","doi":"10.1016/j.jmapro.2026.01.046","DOIUrl":"10.1016/j.jmapro.2026.01.046","url":null,"abstract":"<div><div>The network-structured TiBw/TA15 composites are promising for aerospace but difficult to micromachining. Minimum quantity lubrication (MQL) is attractive for composites machining, yet its effect on surface quality in TiBw/TA15 micromilling remains unclear. The multiphase microstructures of TiBw/TA15 induce brittle-plastic removal and accelerates tool wear. Consequently, the MQL lubrication and tool wear are tightly coupled in evaluating surface quality, the mechanistic elucidation of MQL and machining-parameter effects remain challenging. To address this gap, this study integrates the computational fluid dynamics (CFD) modeling of oil-mist delivery with finite-element analysis (FEA) of multiphase material removal to interpret the results of systematic micromilling experiments across increasing cutting distances. The results show that MQL improves surface quality relative to dry cutting by suppressing the irregular plastic flow of TA15, while TiBw fractures remain but contribute less to surface roughness. The parameter effects are stage-dependent: In initial wear (≤20 mm), radial cutting depth governs the surface roughness through lubrication effectiveness and tool edge geometry, and a moderate value of 60 μm is recommended. In stable wear (>20 mm), spindle speed becomes dominant by altering the lubricant residence and matrix plastic deformation, and the high value of 30,000 rpm is discouraged. A small feed rate (3 μm/tooth) is not recommended due to the intensified ploughing effect and tool wear. MQL ensures consistent surface roughness values remaining under 300 nm, even as tool wear occurs. These findings could provide critical guidance for precision machining of TiBw/TA15 composites.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 271-285"},"PeriodicalIF":6.8,"publicationDate":"2026-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981114","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-17DOI: 10.1016/j.jmapro.2026.01.013
Yue Zhang , Xian Wang , Tao Wang , Changyou Xu , Tao Shi , Penghui Guo , Xiaocong He , Lin Li
The growing demand for lightweight, high-performance joints in aerospace is limited by cracking and non-uniformity during high-strength plate clinching. To overcome these challenges, this study employs ultrasonic vibration-assisted clinching of TA1 titanium alloy, focusing on its forming performance, microstructure, and mechanical properties within the ultrasonic vibration-assisted clinching process. Test results indicate that under ultrasonic vibration-assisted clinching conditions with an amplitude of 10.58 μm, the riveting force is reduced by 23.7% compared to conventional processes. Single-factor experiments determined that the optimal joint clinching performance was achieved with an optimized punch and die combination, a clinching speed of 300 mm/min, and an amplitude of 10.58 μm. Electron backscatter diffraction and microhardness analysis revealed that ultrasonic vibration promoted dynamic recrystallization and grain boundary migration, resulting in grain refinement and improved texture orientation distribution. This enhanced the material's plastic flow capability and structural uniformity. Compared to conventional processes, microhardness increased by 18.72% and 11.75% for the upper and lower plates, respectively, enhancing joint stiffness and load-bearing capability. Regarding mechanical properties, the tensile strength, cross-peel strength, and T-peel strength of ultrasonically assisted clinched joints improved by 12.5%, 16.9%, and 32.88%, respectively, with significantly enhanced energy absorption capacity. Fatigue testing revealed that ultrasonically assisted clinched joints exhibited longer lifetimes than conventional imprint joints across multiple load levels. Fracture surface and energy spectrum analyses indicated that fatigue cracks primarily originated in the micro-wear zone between plates. Simultaneously, ultrasonic vibration suppressed rapid crack propagation, demonstrating the process's ability to effectively delay crack evolution and enhance structural reliability. In summary, ultrasonic vibration-assisted clinching reduces forming energy consumption, optimizes microstructural organization, and enhances joint mechanical properties. This technique offers an efficient, low-carbon solution for lightweight connections in high-strength titanium alloys and other difficult-to-form materials, holding significant engineering implications for aerospace structural manufacturing.
{"title":"Ultrasonic vibration-enhanced clinching process for TA1 titanium alloy: Forming characteristics and mechanical properties","authors":"Yue Zhang , Xian Wang , Tao Wang , Changyou Xu , Tao Shi , Penghui Guo , Xiaocong He , Lin Li","doi":"10.1016/j.jmapro.2026.01.013","DOIUrl":"10.1016/j.jmapro.2026.01.013","url":null,"abstract":"<div><div>The growing demand for lightweight, high-performance joints in aerospace is limited by cracking and non-uniformity during high-strength plate clinching. To overcome these challenges, this study employs ultrasonic vibration-assisted clinching of TA1 titanium alloy, focusing on its forming performance, microstructure, and mechanical properties within the ultrasonic vibration-assisted clinching process. Test results indicate that under ultrasonic vibration-assisted clinching conditions with an amplitude of 10.58 μm, the riveting force is reduced by 23.7% compared to conventional processes. Single-factor experiments determined that the optimal joint clinching performance was achieved with an optimized punch and die combination, a clinching speed of 300 mm/min, and an amplitude of 10.58 μm. Electron backscatter diffraction and microhardness analysis revealed that ultrasonic vibration promoted dynamic recrystallization and grain boundary migration, resulting in grain refinement and improved texture orientation distribution. This enhanced the material's plastic flow capability and structural uniformity. Compared to conventional processes, microhardness increased by 18.72% and 11.75% for the upper and lower plates, respectively, enhancing joint stiffness and load-bearing capability. Regarding mechanical properties, the tensile strength, cross-peel strength, and T-peel strength of ultrasonically assisted clinched joints improved by 12.5%, 16.9%, and 32.88%, respectively, with significantly enhanced energy absorption capacity. Fatigue testing revealed that ultrasonically assisted clinched joints exhibited longer lifetimes than conventional imprint joints across multiple load levels. Fracture surface and energy spectrum analyses indicated that fatigue cracks primarily originated in the micro-wear zone between plates. Simultaneously, ultrasonic vibration suppressed rapid crack propagation, demonstrating the process's ability to effectively delay crack evolution and enhance structural reliability. In summary, ultrasonic vibration-assisted clinching reduces forming energy consumption, optimizes microstructural organization, and enhances joint mechanical properties. This technique offers an efficient, low-carbon solution for lightweight connections in high-strength titanium alloys and other difficult-to-form materials, holding significant engineering implications for aerospace structural manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 298-316"},"PeriodicalIF":6.8,"publicationDate":"2026-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024766","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-17DOI: 10.1016/j.jmapro.2026.01.032
Rui Xu , Xinfei Zhang , Ce Wang , XinYue Li , Hangze Zhou , Shuye Zhang , Tong Wu , Fugang Lu , Peng He , Tiesong Lin , Panpan Lin , Xiaoming Duan
A novel low-temperature bonding approach via the Al-Si-Mg inactive interlayer was proposed to fabricate Al/AlN joints for the first time, achieving a shear strength of 105.2 MPa and a thermal conductivity as high as 216.1 W/(m·K). The joints comprised nanoscale Mg-Al-O compounds, α-Al, and Si phases. By the deoxidation reaction of Mg atoms in the interlayer with AlNxOy of the AlN surface, Mg3Al14O24 was formed and the AlN with a relatively high adsorption energy was exposed. Thus, the AlN was bonding with Al to achieve a seamless and robust Al/AlN direct-bond interface. The influence of temperature on the mechanical properties and heat transfer characteristics of joints was systematically examined. By increasing the temperature to eliminate the primary Si, the joint strength peaked at 105.2 MPa, surpassing that of the metal/AlN joints brazed at higher temperatures by active brazing. Through adjusting the temperature to inhibit the diffusion of Si atoms, the lattice distortion of Al was decreased, and the best thermal conductivity reached 216.1 W/(m·K), far exceeding that of Cu/AlN joints using active brazing or other methods. This bonding approach provides a novel strategy for the high-performance manufacturing of AlN substrates.
首次提出了一种利用Al- si - mg非活性中间层制备Al/AlN接头的新型低温结合方法，其抗剪强度达到105.2 MPa，导热系数高达216.1 W/（m·K）。接头由纳米级Mg-Al-O化合物、α-Al和Si相组成。中间层中的Mg原子与AlN表面的AlNxOy发生脱氧反应，生成Mg3Al14O24，暴露出具有较高吸附能的AlN。因此，AlN与Al键合，实现了无缝且坚固的Al/AlN直接键合界面。系统地研究了温度对接头力学性能和传热特性的影响。通过提高钎焊温度消除初生Si，接头强度达到105.2 MPa，超过了活性钎焊在较高温度下钎焊的金属/AlN接头。通过调节温度抑制Si原子的扩散，降低了Al的晶格畸变，最佳导热系数达到216.1 W/(m·K)，远远超过了采用活性钎焊或其他方法的Cu/AlN接头。这种键合方法为AlN基板的高性能制造提供了一种新的策略。
{"title":"Achieving high mechanical properties and outstanding thermally conductive Al/AlN direct-bonded joints through interfacial oxide barrier elimination","authors":"Rui Xu , Xinfei Zhang , Ce Wang , XinYue Li , Hangze Zhou , Shuye Zhang , Tong Wu , Fugang Lu , Peng He , Tiesong Lin , Panpan Lin , Xiaoming Duan","doi":"10.1016/j.jmapro.2026.01.032","DOIUrl":"10.1016/j.jmapro.2026.01.032","url":null,"abstract":"<div><div>A novel low-temperature bonding approach via the Al-Si-Mg inactive interlayer was proposed to fabricate Al/AlN joints for the first time, achieving a shear strength of 105.2 MPa and a thermal conductivity as high as 216.1 W/(m·K). The joints comprised nanoscale Mg-Al-O compounds, α-Al, and Si phases. By the deoxidation reaction of Mg atoms in the interlayer with AlN<sub>x</sub>O<sub>y</sub> of the AlN surface, Mg<sub>3</sub>Al<sub>14</sub>O<sub>24</sub> was formed and the Al<img>N with a relatively high adsorption energy was exposed. Thus, the Al<img>N was bonding with Al to achieve a seamless and robust Al/AlN direct-bond interface. The influence of temperature on the mechanical properties and heat transfer characteristics of joints was systematically examined. By increasing the temperature to eliminate the primary Si, the joint strength peaked at 105.2 MPa, surpassing that of the metal/AlN joints brazed at higher temperatures by active brazing. Through adjusting the temperature to inhibit the diffusion of Si atoms, the lattice distortion of Al was decreased, and the best thermal conductivity reached 216.1 W/(m·K), far exceeding that of Cu/AlN joints using active brazing or other methods. This bonding approach provides a novel strategy for the high-performance manufacturing of AlN substrates.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 286-297"},"PeriodicalIF":6.8,"publicationDate":"2026-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981112","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-17DOI: 10.1016/j.jmapro.2026.01.029
Yadong Li , Bing Liu , Zhenghua Chang , Zhaofu Zhang , Wengen Ouyang , Zishang Liu , Quanyu Jiang , Yizhe Liu , Anyi Huang , Yuxin Wu , Zheng Hu , Hai Lan , Ming Han , Yunjian Bai , Kun Zhang , Bingchen Wei
Tribological materials play a critical role in high-end fields such as aerospace, rail transportation, manufacturing processes and energy equipment. However, their friction and wear behaviors are highly complex, governed by the coupled effects of multi-scale and multi-physics interactions. Traditional research approaches, which rely heavily on experiments and empirical knowledge, are costly, time-consuming, and often insufficient to uncover the underlying mechanisms. With the rapid development of artificial intelligence (AI), machine learning (ML) has emerged as a powerful tool in tribology research, leading to the introduction of the concept of tribo-informatics. This review systematically summarizes the methodological framework of ML in tribology, covering data acquisition, feature selection, model selection and optimization, performance evaluation and validation, as well as result interpretation. Key methodological advances, including data augmentation, physics-informed approaches, and interpretability techniques, are emphasized and systematically discussed. Representative applications demonstrate that data-driven interpretable learning, multi-source data fusion, and physics-informed ML (PIML) models can enhance prediction accuracy and robustness while revealing fundamental tribological mechanisms. Moreover, ML has been widely applied to the design and performance optimization of novel tribological materials, accelerating the materials development cycle. Finally, the future prospects of tribo-informatics are outlined, highlighting high-quality database construction, physics-driven integration, interpretability enhancement, and small-sample learning as key research trends. This review aims to provide a systematic methodological reference for tribology research and to promote the paradigm shift from experience-driven to data–mechanism integrated approaches.
{"title":"Machine learning in tribology: A review on framework, case studies, and future perspectives","authors":"Yadong Li , Bing Liu , Zhenghua Chang , Zhaofu Zhang , Wengen Ouyang , Zishang Liu , Quanyu Jiang , Yizhe Liu , Anyi Huang , Yuxin Wu , Zheng Hu , Hai Lan , Ming Han , Yunjian Bai , Kun Zhang , Bingchen Wei","doi":"10.1016/j.jmapro.2026.01.029","DOIUrl":"10.1016/j.jmapro.2026.01.029","url":null,"abstract":"<div><div>Tribological materials play a critical role in high-end fields such as aerospace, rail transportation, manufacturing processes and energy equipment. However, their friction and wear behaviors are highly complex, governed by the coupled effects of multi-scale and multi-physics interactions. Traditional research approaches, which rely heavily on experiments and empirical knowledge, are costly, time-consuming, and often insufficient to uncover the underlying mechanisms. With the rapid development of artificial intelligence (AI), machine learning (ML) has emerged as a powerful tool in tribology research, leading to the introduction of the concept of tribo-informatics. This review systematically summarizes the methodological framework of ML in tribology, covering data acquisition, feature selection, model selection and optimization, performance evaluation and validation, as well as result interpretation. Key methodological advances, including data augmentation, physics-informed approaches, and interpretability techniques, are emphasized and systematically discussed. Representative applications demonstrate that data-driven interpretable learning, multi-source data fusion, and physics-informed ML (PIML) models can enhance prediction accuracy and robustness while revealing fundamental tribological mechanisms. Moreover, ML has been widely applied to the design and performance optimization of novel tribological materials, accelerating the materials development cycle. Finally, the future prospects of tribo-informatics are outlined, highlighting high-quality database construction, physics-driven integration, interpretability enhancement, and small-sample learning as key research trends. This review aims to provide a systematic methodological reference for tribology research and to promote the paradigm shift from experience-driven to data–mechanism integrated approaches.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 243-270"},"PeriodicalIF":6.8,"publicationDate":"2026-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981113","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-16DOI: 10.1016/j.jmapro.2026.01.001
Haiqing Chen, Jixiang Yang, Qi Qi, Han Ding
High-precision curved parts grinding must meet strict material removal control and surface quality constraint at the same time. In actual grinding process, the tool wear will cause its material removal ability to gradually decay and simultaneously induce changes in workpiece surface roughness, while existing studies have not considered the dynamic impact of tool wear to simultaneously guarantee material removal accuracy and surface quality. This paper proposes a robotic grinding parameter optimization method considering tool wear to guarantee material removal accuracy while maintain surface quality. Firstly, after quantifying the tool wear over usage time, the material removal depth coefficient under different process parameters at different times is predicted by multivariate Gaussian process regression, and a material removal model considering tool wear is developed. Secondly, a surface roughness prediction model is constructed in combination with the tool wear degree to characterize the influence of tool wear on surface quality. On this basis, a robotic grinding process parameter optimization algorithm considering tool wear is developed, which achieves accurate compensation of material removal accuracy by adjusting process parameters, while ensuring that the surface quality meets the requirements. Finally, experimental verification results show that compared with the robotic grinding process parameter optimization method without considering tool wear and surface roughness constraint, the proposed method significantly improves the material removal accuracy and surface quality of the curved parts after grinding.
{"title":"A robotic grinding parameter optimization approach considering tool wear to guarantee material removal accuracy and surface quality","authors":"Haiqing Chen, Jixiang Yang, Qi Qi, Han Ding","doi":"10.1016/j.jmapro.2026.01.001","DOIUrl":"10.1016/j.jmapro.2026.01.001","url":null,"abstract":"<div><div>High-precision curved parts grinding must meet strict material removal control and surface quality constraint at the same time. In actual grinding process, the tool wear will cause its material removal ability to gradually decay and simultaneously induce changes in workpiece surface roughness, while existing studies have not considered the dynamic impact of tool wear to simultaneously guarantee material removal accuracy and surface quality. This paper proposes a robotic grinding parameter optimization method considering tool wear to guarantee material removal accuracy while maintain surface quality. Firstly, after quantifying the tool wear over usage time, the material removal depth coefficient under different process parameters at different times is predicted by multivariate Gaussian process regression, and a material removal model considering tool wear is developed. Secondly, a surface roughness prediction model is constructed in combination with the tool wear degree to characterize the influence of tool wear on surface quality. On this basis, a robotic grinding process parameter optimization algorithm considering tool wear is developed, which achieves accurate compensation of material removal accuracy by adjusting process parameters, while ensuring that the surface quality meets the requirements. Finally, experimental verification results show that compared with the robotic grinding process parameter optimization method without considering tool wear and surface roughness constraint, the proposed method significantly improves the material removal accuracy and surface quality of the curved parts after grinding.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 228-242"},"PeriodicalIF":6.8,"publicationDate":"2026-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981111","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-16DOI: 10.1016/j.jmapro.2026.01.028
Ruiyan Jia , Haichao Li , Fangkai Wei , Jing Li , Yixuan Ma , Fei Liu , Lianheng Guo
Robotic narrow-gap gas metal arc welding (NG-GMAW) is being increasingly adopted in industrial manufacturing. A key challenge is the resulting demand for real-time monitoring of welding fusion quality in intelligent systems. This study proposes a Frequency-Attention Enhanced ConvNeXt (FAE-ConvNeXt) model for predicting fusion instability in robotic NG-GMAW. The proposed model enhances prediction accuracy and industrial applicability through the integration of multidimensional information and targeted handling of temperature characteristics. First, a Multi-Scale Frequency Enhancement Module (MSFEM) is developed. Based on infrared thermal images, MSFEM analyzes the frequency domain features of the molten pool. This algorithm is designed to extract subtle defect features that are often imperceptible in the spatial domain. Subsequently, a Thermal Gradient Adaptive Attention Module (TGAAM) is introduced to capture abrupt temperature transitions. The temperature gradient is incorporated as a physical prior into the attention computation. Through dynamic adjustment of attention regions and the fusion of thermal gradient features, TGAAM achieves a comprehensive analysis of the molten pool. Finally, the integration of these modules into ConvNeXt blocks allows for a coherent fusion of multi-domain features, including spatial, frequency, and thermal gradient information. Experimental results demonstrate that the proposed FAE-ConvNeXt model achieves a prediction accuracy of 98.51%. Visualization analysis reveals that the model concentrates on molten pool regions characterized by sharp changes in temperature gradients when predicting the fusion states. Compared with traditional algorithms, this model overcomes the limitations of single-dimensional feature extraction. By fully leveraging the rich information in molten pool infrared images, this approach provides a robust solution for enhancing the intelligence and stability of robotic NG-GMAW.
{"title":"Fusion instability prediction and mechanism exploration in robotic narrow-gap GMAW via frequency-attention enhanced ConvNeXt","authors":"Ruiyan Jia , Haichao Li , Fangkai Wei , Jing Li , Yixuan Ma , Fei Liu , Lianheng Guo","doi":"10.1016/j.jmapro.2026.01.028","DOIUrl":"10.1016/j.jmapro.2026.01.028","url":null,"abstract":"<div><div>Robotic narrow-gap gas metal arc welding (NG-GMAW) is being increasingly adopted in industrial manufacturing. A key challenge is the resulting demand for real-time monitoring of welding fusion quality in intelligent systems. This study proposes a Frequency-Attention Enhanced ConvNeXt (FAE-ConvNeXt) model for predicting fusion instability in robotic NG-GMAW. The proposed model enhances prediction accuracy and industrial applicability through the integration of multidimensional information and targeted handling of temperature characteristics. First, a Multi-Scale Frequency Enhancement Module (MSFEM) is developed. Based on infrared thermal images, MSFEM analyzes the frequency domain features of the molten pool. This algorithm is designed to extract subtle defect features that are often imperceptible in the spatial domain. Subsequently, a Thermal Gradient Adaptive Attention Module (TGAAM) is introduced to capture abrupt temperature transitions. The temperature gradient is incorporated as a physical prior into the attention computation. Through dynamic adjustment of attention regions and the fusion of thermal gradient features, TGAAM achieves a comprehensive analysis of the molten pool. Finally, the integration of these modules into ConvNeXt blocks allows for a coherent fusion of multi-domain features, including spatial, frequency, and thermal gradient information. Experimental results demonstrate that the proposed FAE-ConvNeXt model achieves a prediction accuracy of 98.51%. Visualization analysis reveals that the model concentrates on molten pool regions characterized by sharp changes in temperature gradients when predicting the fusion states. Compared with traditional algorithms, this model overcomes the limitations of single-dimensional feature extraction. By fully leveraging the rich information in molten pool infrared images, this approach provides a robust solution for enhancing the intelligence and stability of robotic NG-GMAW.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 217-227"},"PeriodicalIF":6.8,"publicationDate":"2026-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981110","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-15DOI: 10.1016/j.jmapro.2026.01.033
Chao Zhang , Yinghui Ren , Maojun Li , Chengyang Yu , Minghui Liao , Xiaolin Yu , Qiding Yang
The anisotropy of carbon fiber reinforced plastic (CFRP) leads to an inhomogeneous heat-affected zone (HAZ, the laser-irradiated region with thermal-induced structural and property degradation), which significantly impacts the stability and quality of laser-assisted robotic milling (L-ARM). Based on the heat conduction model and robotic milling platform, this study developed novel finite element models of different zones of HAZ, including matrix recession zone (MRZ, with severe matrix decomposition) and transition zone (TZ, with partial matrix degradation), to reveal the material removal mechanism under different thermal effects. The results show that the energy per unit length (El) and temperature distribution significantly impact the morphology and extent of HAZ. Matrix degradation and fiber rebound in the MRZ lead to burr formation. Fiber shearing in the TZ under minor thermal effects produces superior surface quality. Conversely, major thermal effect results in fiber bending and matrix cracks. Notably, cutting force fluctuations are higher in the TZ than in the MRZ, reaching a maximum of 31.74 N during milling of TZ under minor thermal effects (El = 150 J/mm), which significantly affects the stability and quality of robotic milling.
{"title":"Thermal effects on the material removal mechanism in laser-assisted milling of CFRP","authors":"Chao Zhang , Yinghui Ren , Maojun Li , Chengyang Yu , Minghui Liao , Xiaolin Yu , Qiding Yang","doi":"10.1016/j.jmapro.2026.01.033","DOIUrl":"10.1016/j.jmapro.2026.01.033","url":null,"abstract":"<div><div>The anisotropy of carbon fiber reinforced plastic (CFRP) leads to an inhomogeneous heat-affected zone (HAZ, the laser-irradiated region with thermal-induced structural and property degradation), which significantly impacts the stability and quality of laser-assisted robotic milling (L-ARM). Based on the heat conduction model and robotic milling platform, this study developed novel finite element models of different zones of HAZ, including matrix recession zone (MRZ, with severe matrix decomposition) and transition zone (TZ, with partial matrix degradation), to reveal the material removal mechanism under different thermal effects. The results show that the energy per unit length (<em>E</em><sub><em>l</em></sub>) and temperature distribution significantly impact the morphology and extent of HAZ. Matrix degradation and fiber rebound in the MRZ lead to burr formation. Fiber shearing in the TZ under minor thermal effects produces superior surface quality. Conversely, major thermal effect results in fiber bending and matrix cracks. Notably, cutting force fluctuations are higher in the TZ than in the MRZ, reaching a maximum of 31.74 N during milling of TZ under minor thermal effects (<em>E</em><sub><em>l</em></sub> = 150 J/mm), which significantly affects the stability and quality of robotic milling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 199-216"},"PeriodicalIF":6.8,"publicationDate":"2026-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981210","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-15DOI: 10.1016/j.jmapro.2026.01.031
Tao Liu , Shun Xie , Jianglin Zou , Jing Wang , Kaikai Shi , Yuxuan Zhang , Qiang Wu
Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.
{"title":"Oxidation and photothermal energy conversion at the laser-induced vapor–liquid interface during laser spot welding","authors":"Tao Liu , Shun Xie , Jianglin Zou , Jing Wang , Kaikai Shi , Yuxuan Zhang , Qiang Wu","doi":"10.1016/j.jmapro.2026.01.031","DOIUrl":"10.1016/j.jmapro.2026.01.031","url":null,"abstract":"<div><div>Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 188-198"},"PeriodicalIF":6.8,"publicationDate":"2026-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981208","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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